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Additive-Manufacturing-Qualification-Certification-and-Implementation (1).pptx
- 1. • Background • Benefits •Additive Manufacturing Processes • Qualification • Certification • Implementation • Summary Outline 1
- 2. • Traditional Manufacturing •Materials Manufacturing • Rolling, Casting, Forging etc. • To meet mechanical properties by Heat Treatment etc. • Machining • To meet dimension and special features by CNC machine, Lathe etc • Welding • To join multi-pieces together Background 2 • Additive Manufacturing • Integrated process with materials manufacturing machining and welding • Add materials layer by layer • Controlled by sliced CAD model, software and hardware
- 3. Benefits 3 Manufacturing On-Demand Prototype newdesign Reduce inventory of spare parts Remanufacture obsolete parts Reduce lead-time Repair or Special Feature Apply functional/new materials Add specific features Repair damaged parts Manufacturing End Use Components Increase design freedom for complex shapes Integrate multiple pieces to single part Add materials for weight saving Small Batch Production Cost-effective small volume production Small batch production under dynamic vs static build Digital Scanning Digital Design Digital Engineering Digital Manufacturing
- 4. Additive Manufacturing Processes 4 •Objectives of ABS are Qualification of AM Facilities to enable reliable quality products through a developed certification scheme which focuses on: • Design verification and validation • Additive manufacturing procedure approval • Initial and periodic factory audits
- 5. Additive Manufacturing Processes 5 Categoriesof Additive Manufacturing Processes Materials Extrusion Material Jetting Vat Photopolymerization Sheet Lamination Binder Jetting Direct Energy Deposition Powder Bed Fusion
- 6. Powder Bed FusionExample 6 • Powder Bed Fusion (PBF): An AM process in which thermal energy selectively fuses regions of a powder bed. Example of Build Diagram Showing Location, Number, Type, and Orientation of Test Specimens and Reference Parts Distance Between Parts Nesting Type and Arrangement of Part and Support Structures Powder Roller Powder Supply Build Platform / Baseplate Powder Matrix Energy Source & Beam Controller
- 7. Directed Energy DepositionExample 7 • Direct Energy Deposition (DED): An AM process in which focused thermal energy is used to fuse materials by melting as they are being deposited. X Y Z Process Coordinate System Multi-Axis Arm Maximum Working Envelope / Build Volume Deposition Path (Contour or Fill Types, Contour Shown) Build Platform or Existing Part Part Fixture (Can be Static or Dynamic)
- 8. Binder Jetting Examples 8 •Binder Jetting (BJ): An AM process in which liquid bonding agent is selectively deposited to join powder materials Powder Spreader and / or Inkjet Loose Powder Bound Powder Build Box Direct Metal Production Indirect Metal Production To Infiltration & Heat Treatment Bound Metal Powder Parts Bound Sand Mold To Casting Facility Bound Part Cores (if applicable)
- 9. Additive Manufacturing Processes 9 AWSD20.1 Subcategories of Metal Additive Manufacturing Processes Abbreviation Laser Powder Bed Fusion L-PBF Electron Beam Powder Bed Fusion EB-PBF Laser Directed Energy Deposition L-DED Electron Beam Directed Energy Deposition EB-DED Plasma Arc Directed Energy Deposition PA-DED Gas Tungsten Arc Directed Energy Deposition GTA-DED Gas Metal Arc Directed Energy Deposition GMA-DED
- 10. Qualification 10 • Critical/Severity levelfor application may be determined and agreed. Appropriate AM process is selected and routing out. June 2016, International Journal of Fatigue 94, DOI: 10.1016/j.ijfatigue.2016.07.005 Michael Gorelik, Federal Aviation Administration • Critical: • Failure would cause significant danger to personnel, loss of control, loss of a system, loss of a major component or an operating penalty. • Semi-critical • Failure would reduce the overall strength of the equipment or system or preclude the intended functioning or use of equipment, but loss of the system or the endanger of personnel would not occur. • Non-critical • Failure would not affect the operation of the system or endanger personnel. AWS D20.1
- 11. Qualification 11 Feedstock (Powder/Wire) Part/Coupon Design (CAD files,functional and technical design specs) Additive Manufacturing Service Provider • Production Parts • Reference Parts • Test Samples • Test Artifacts Heat Treatment (AM processes can build significant residual stresses) Cleaning/Machining (Not trivial if complex geometry) Testing • Destructive • Nondestructive • Functional Application Partial Black Box Machine operations are observed, but data may not be well-understood or shareable.
- 12. Qualification 12 Additive Manufacturing QualificationProcess Cradle to Grave File Part Design Package Part Inspection and Testing Package Part Manufacturing Description Process Configuration and Workflow Diagram Additive Manufacturing Project Setup Initial Cradle to Grave File Population Feasibility Stage Verification Stage Pre-Production Validation Stage Production Stage Qualification Stages
- 13. Qualification 13 • Sample AdditiveManufacturing Qualification Record: Machine Qualification or Procedure Qualification Record: • General • Build Platform • Feedstock • Machine • Environment • Build Parameters • Post Processing • Examination and Testing Results (additional testing by design requirements) Refer to AWS D20.1
- 14. Qualification 14 • Challenges • Process-Microstructure- Properties •Mechanical properties (anisotropy, fracture toughness, fatigue properties etc.) • Process-Feature-Function • Non-destructive testing • Verification and validation in manufacturability, maintainability and reliability http://senvol.com/database/
- 15. Qualification 15 • Fit-For-Service • Severityzone based • Engineering Critical Assessment • BS 7910 • Crackwise developed by the welding institute, UK • Risk based • Statistics data of traditional manufacturing vs additive manufacturing 0 10 20 30 40 50 0 20 40 60 80 Initial Flaw Height, mm Initial Flaw Length, 2C, mm CTOD Non-CTOD Expon. (CTOD) Expon. (Non- CTOD)
- 16. Certification 16 • Metal AdditiveManufacturing Component • Product Design Assessment • Manufacturing Assessment • Product Quality Assessment • Unit Certification • Additive Manufacturing Service Provider • Quality Management System • Additive Manufacturing Capability Request for Approval Instruction Letter Submittal Review Audit Maturity Letter or Provisional Approval Letter Capability Demo. Approval Letter or Certificate
- 17. Implementation 17 • Additive manufacturingprocess is continuously improved using a close-loop product lifecycle management. Approved Design Approved Raw Material Supplier Outsourcing Suppliers Approved AM Machine Procedure Operator Approved Production Plan Accepted Inspection and Testing Report Traceable during Operation Performance Evaluation or Failure Analysis
- 18. • Metal AMfor end-use can bring many benefits for shipping industry. • Manufacturing on-demand • End-use components • Repair or add features • Small batch production • Three common metal AM processes: • PBF • DED • Binder Jetting • NTQ for other processes requested • ABS streamlined qualification scheme, certification and implementation process. • Additive Manufacturing Service Provider • Metal Additive Manufacturing Components Summary 18
- 19. • ABS Advisory https://ww2.eagle.org/content/dam/eagle/advisories-and- debriefs/ABS_Additive_Manufacturing_Advisory_17294.pdf •ABS Guidance Notes https://ww2.eagle.org/content/dam/eagle/rules-and-guides/current/other/299- gn-on-additive-manufacturing-2018/additive-manufacturing-gn-sept18.pdf • ABS Steel Vessel Rules https://ww2.eagle.org/en/rules-and-resources/rules-and-guides.html • ABS Current Engagement Joint Development/Industry Project to improve the technology readiness level of additive manufacturing technology for marine and offshore application. Summary 19
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